Tonneau system for use with a pickup truck

ABSTRACT

A tonneau system for use with a cargo box of a pickup truck. The tonneau system includes a pair of side rails for mounting to the sidewalls of the cargo box and a tonneau cover having at least two tonneau sections and being moveable relative to one another between an unfolded state and a folded state. In the unfolded state the tonneau sections substantially covering the cargo box and in the folded state the tonneau sections being arranged in a stack. The stack of tonneau sections is pivotally connected to the side rails by a pivot connection that is moveable between secure and release positions. In the secure position, the stack being retainingly engaged with the side rails and, in the release position, the stack being removably engaged with the side rails whereby the stack is removable from the cargo box while the side rails remain mounted therewith.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.15/771,957, filed Apr. 27, 2018, which is a § 371 national stageapplication of PCT/CA2016/051247, filed Oct. 28, 2016, which claims thebenefit of U.S. provisional application No. 62/248,831, filed Oct. 30,2015. The entire contents of each of above referenced applications isherein incorporated by reference.

TECHNICAL FIELD

The following relates generally to tonneau covers. In particular, thefollowing relates to a tonneau system for use with a pickup truck.

SUMMARY

In one aspect of the invention, a tonneau system for use with a cargobox of a pickup truck is provided. The cargo box typically includesopposing first and second sidewalls and also includes a front sidewallextending between the first and second sidewalls at one end thereof anda rear sidewall extending between the first and second sidewalls atanother end thereof. The tonneau system includes: a first side railconfigured to be respectively mounted to the first sidewall of the cargobox; a second side rail configured to be respectively mounted to thesecond sidewall of the cargo box; a tonneau cover having at least twotonneau sections including a first tonneau section and a second tonneausection, the tonneau sections being moveable relative to one anotherbetween an unfolded state and a folded state, in the unfolded state thetonneau sections substantially covering the cargo box, in the foldedstate the tonneau sections being arranged in a stack with the tonneausections arranged one atop another, the first tonneau section being thetonneau section located closest to the front sidewall of the cargo boxin the unfolded state; and the stack of tonneau sections being pivotallyconnected to at least one of the first and second side rails by a pivotconnection, the pivot connection including first and second portionsbeing moveable between secure and release positions, in the secureposition the stack being retainingly engaged with the first and secondside rails, in the release position the stack being removably engagedwith the first and second side rails whereby the stack is removable fromthe cargo box while the first and second side rails remain mountedtherewith.

In another aspect, one of the first and second portions is mounted tothe stack and the other of the first and second portions is mounted tothe first side rail.

In a further aspect, one of the first and second portions is mounted tothe first tonneau section of the stack and the other of the first andsecond portions is mounted to the first side rail.

In an additional aspect, the first portion is a pin and the secondportion includes a pin slot, the pin being received in the pin slot.

In another aspect, the pin projects from a side of the first tonneausection that is located immediately adjacent to the first side rail whenthe tonneau cover is in the unfolded position.

In a further aspect, the first and second side rails each include a topside and a lateral side, the lateral sides of the first and second siderails being located generally opposite from one another when the firstand second side rails are mounted to the first and second sidewalls ofthe cargo box, the top side of the first and second side rails facingout of the cargo box when the first and second side rails are mounted tothe first and second sidewalls of the cargo box, the pin slot isprovided in the first side rail and includes a top opening formed in thetop side of the first side rail, the pin slot further including achannel extending from the top opening.

In an additional aspect, the channel is open on the lateral side of thefirst side rail.

In another aspect, at least a portion of the pin has a cross-section ofa non-round shape presenting a different width in a direction of the topopening in each of the secure position and the release position, atleast a portion of the top opening having a width corresponding to thewidth of the non-round shape in the release position whereby the pin inthe release position can pass through the top opening and the stack oftonneau sections removed from the side rails.

In a further aspect, the width of the non-round shape in the releaseposition is smaller than the width of the non-round shape in the secureposition.

In an additional aspect, the non-round shape is provided as a protrusionof the pin.

In another aspect, the protrusion is on an end of the pin

In a further aspect, the non-round shape is provided as a flatprotrusion of the pin.

In an additional aspect, adjacent to the non-round shape the pin isprovided with a cross-section having a round shape.

In another aspect, the non-round shape is provided as a protrusion ofthe pin.

In a further aspect, the channel extends along a length of the firstside rail.

In an additional aspect, the pin is slidingly received within thechannel.

In another aspect, the stack of tonneau sections is pivotally connectedto each of the first and second side rails by a pivot connection.

In a further aspect, the secure position of the pivot connection, thefirst tonneau section is generally parallel to a plane defined by thefirst and second side rails.

In an additional aspect, in the secure position of the pivot connection,the first tonneau section is horizontal oriented.

In another aspect, in the release position of the pivot connection, thefirst tonneau section is generally perpendicular to a plane defined bythe first and second side rails.

In a further aspect, in the release position of the pivot connection,the first tonneau section is vertically oriented.

In an additional aspect, the pivot connection is spaced apart from anend of the at least one of the first and second side rails.

In another aspect, the tonneau sections are one of rigid and flexible.

In a further aspect, the first side rail includes a locking bracketmoveable along the first side rail between an open position and alocking position, in the locking position the locking bracket engagingone of the first and second portions.

In an additional aspect, the first portion is a pin and the secondportion includes a pin slot, the pin being received in the pin slot andthe locking bracket engaging the pin in the locking position.

In another aspect, the locking bracket includes a locking slot, thelocking slot engaging the pin in the locking position.

In a further aspect, the locking bracket is biased between the openposition and the locking position.

In an additional aspect, the locking bracket includes a protuberance andthe first side rail includes at least two indentations, the lockingbracket being secured in the open positon by the protuberance engagingone of the indentations and being secured in the locking position by theprotuberance engaging the other of the indentations.

In a further aspect of the invention, a tonneau system for use with apickup truck is provided, the tonneau system including: a tonneau cover,comprising: a plurality of rigid tonneau sections, the plurality havingat least a first tonneau section and a second tonneau section; a firsthinge system coupling the first tonneau section to the second tonneausection, enabling stacking and expanding of the first tonneau sectionrelative to the second tonneau section; and a frame, comprising a firstside rail securable to a first side of a cargo box of a pickup truck anda second side rail securable to a second side of the cargo box of thepickup truck, the frame being pivotally connected to the first tonneausection distal to the first hinge system; at least one latch releaseablysecuring the tonneau cover to the first side rail and to the second siderail and, when released, enables the stacked tonneau sections to dependinto the cargo box.

The tonneau system may further comprise at least a second hinge systemcoupling a third tonneau section to the second tonneau section along anedge of the second tonneau section spaced apart from the first hingesystem.

The first hinge system may comprise a piano hinge. The second hingesystem may comprise a pair of piano hinges coupling a spacer memberbetween the second tonneau section and the third tonneau section.

The first side rail and the second side rail may each comprise a pinslot, and the first tonneau section may have a pair of pins projectingtherefrom at each side thereof, the pins being received in the pin slotsto provide the pivotal connection of the frame to the first tonneausection.

The pin slots may comprise a notched top opening and a generallyrearward-sloping channel.

A cap may be removably securable to the pin slots to prevent the pair ofpins from being removed from the pin slots.

The pins may each comprise a flat protrusion that cooperate with the pinslots to prevent removal of the first tonneau section from the siderails when the first tonneau section is in an extended position.

The flat protrusions may cooperate with the pin slots to permit removalof the first tonneau section from the side rails when the first tonneausection is in a vertical position.

The at least one latch may comprise a catch secured to the side rail anda latchbolt extending from the first tonneau section.

The latchbolt may be disposed upon a flange extending from a bottomsurface of the first tonneau section.

The latchbolt may comprise an actuator causing movement of a cablecoupled to the latchbolts, wherein actuating the actuator causes arelease of the latchbolt from the catch to permit free pivotal movementof the tonneau system.

A tonneau section distal from the first tonneau section may have a pairof latches projecting therefrom at each side thereof, the latches beingsecurable to the side rails to retain the tonneau system in an extendedposition.

The at least one latch may comprise a catch secured to the side rail anda latchbolt extending from the tonneau section.

The latchbolt may be disposed upon a flange extending from a bottomsurface of the tonneau section.

The latchbolt may comprise an actuator causing movement of a cablecoupled to the latchbolts, wherein actuating the actuator causes arelease of the latchbolt from the catch to permit pivoting of thetonneau section.

The pivotal connection may permit pivoting the tonneau cover upwards ordownwards relative to the frame when the tonneau cover is in a nestedposition.

The tonneau system may further comprise a pair of struts pivotallyconnected to the bottom surface of the first tonneau section, the strutscoupleable to the side rails to maintain the stacked tonneau sections ina generally upright position above the cargo box.

The tonneau system may further comprise a dead panel in fixedrelationship to the frame, the dead panel being pivotally coupled to thefirst tonneau section and having a cable-activated release mechanism topermit the first tonneau section to be selectively pivoted thereto.

At least one tonneau section may comprise a solar panel disposed on thetop surface thereof, and the tonneau system couples the solar panel to abattery to store power generated therefrom.

Each tonneau section may be coupled by an electrical cabling systemcomprising a cable extending from a sheath, wherein the cable isdecoupleable to permit removal or replacement of the respective tonneausection.

Each tonneau section and spacers separating each tonneau section maycomprise electrical contacts disposed along edges thereof to permitelectrical coupling among the tonneau sections.

The electrical contacts may be spring-loaded pins.

The frame may comprise a utility track along the top surface of at leastone of the first side rail and the second side rail thereof to permit anattachment to be secured thereto.

The frame may comprise a utility track along the inner side surface ofat least one of the first side rail and the second side rail thereof topermit an attachment to be secured thereto.

The frame may comprise a first utility track along the top surface of atleast one of the first side rail and the second side rail and a secondutility track along the inner side surface of the at least one of thefirst side rail and the second side rail thereof, to permit anattachment to be secured simultaneously to the first utility track andthe second utility track.

These and other aspects are contemplated and described herein. It willbe appreciated that the foregoing summary sets out representativeaspects of a tonneau system to assist skilled readers in understandingthe following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

A greater understanding of the embodiments will be had with reference tothe Figures, in which:

FIG. 1 is a side perspective view of a tonneau system for use with apickup truck in accordance with one embodiment thereof;

FIG. 2a is a top perspective view of the tonneau cover and frame of thetonneau system of FIG. 1;

FIG. 2b is a bottom perspective view of the tonneau cover and frame ofFIG. 2 a;

FIG. 3 shows a left side view of the tonneau cover 28 of FIG. 2 a;

FIG. 4 shows a portion of a side railing of the frame of FIG. 1 having aslot for receiving the tonneau cover;

FIG. 5 shows a portion of a pivot pin of the tonneau cover of FIG. 1 tobe received by the slot of FIG. 4;

FIG. 6 shows the slot of a side rail of FIG. 4 having received the pivotpin of FIG. 5 of the tonneau cover in a stacked state;

FIG. 7 shows the orientation of the pin of FIG. 5 relative to the slotof FIG. 4 when the tonneau cover is in an expanded state covering thecargo box of the pickup truck;

FIG. 8 shows a sectional view of the side rail at line A-A in FIG. 1;

FIG. 9 shows a sectional view of the side rail at line B-B in FIG. 1;

FIG. 10 shows a latch between a front-most tonneau section and the siderail of FIG. 2 in an open position as the stacked tonneau sections arebeing pivoted up out of the cargo box of the pickup truck;

FIG. 11 shows the latch of FIG. 10 after engagement;

FIG. 12 shows the tonneau cover in a stacked state after engagement ofthe latch as shown in FIG. 11;

FIG. 13 shows an end view of a portion of a side rail and a catch ofanother latch for releaseably securing the tonneau cover to the siderail of the frame;

FIG. 14 shows a bottom perspective view of the latch of FIG. 13 afterengagement;

FIG. 15 shows the tonneau cover of FIG. 1 in a stacked state anddepending into the cargo box of the pickup truck;

FIG. 16 shows the tonneau cover of FIG. 1 in a stacked state andoriented vertically above the cargo box of the pickup truck;

FIG. 17 shows the position and orientation of the pin of the tonneaucover inside the slot of FIG. 4 when the tonneau cover is stacked andoriented vertically as shown in FIG. 16;

FIG. 18 shows a side view of the stacked tonneau cover orientedvertically out of the cargo box of FIG. 17;

FIG. 19 shows the stacked tonneau cover being propped above the cargobox via a pair of struts;

FIG. 20 shows a tonneau system similar to that of FIG. 1, wherein solarpanels are positioned at the top surfaces of the tonneau cover sections;

FIG. 21 shows an electrical coupling system for the tonneau coversections of FIG. 20;

FIG. 22 shows a schematic view of the power collection and conversionsystem of the tonneau system of FIG. 20;

FIG. 23 shows an electrical coupling system for the tonneau coversections of FIG. 20 in an alternative embodiment;

FIG. 24 shows a tonneau system in accordance with another embodiment,wherein the front latch is further forward than that of FIG. 1;

FIG. 25 shows a side rail for a tonneau system wherein the slot isdiagonally sloped forward and down;

FIG. 26 is a sectional view of a side rail similar to that of FIG. 8 inaccordance with another embodiment, wherein the side rail is clamped toa horizontal portion of the side wall of the cargo box;

FIG. 27 shows an exemplary fastener for maintaining the tonneau systemin a nested stacked arrangement; and

FIG. 28 shows a bottom view of an alternative tonneau cover arrangementin which a dead panel is provided ahead of the first tonneau section.

DETAILED DESCRIPTION

For simplicity and clarity of illustration, where consideredappropriate, reference numerals may be repeated among the Figures toindicate corresponding or analogous elements. In addition, numerousspecific details are set forth in order to provide a thoroughunderstanding of the embodiments described herein. However, it will beunderstood by those of ordinary skill in the art that the embodimentsdescribed herein may be practiced without these specific details. Inother instances, well-known methods, procedures and components have notbeen described in detail so as not to obscure the embodiments describedherein. Also, the description is not to be considered as limiting thescope of the embodiments described herein.

Various terms used throughout the present description may be read andunderstood as follows, unless the context indicates otherwise: “or” asused throughout is inclusive, as though written “and/or”; singulararticles and pronouns as used throughout include their plural forms, andvice versa; similarly, gendered pronouns include their counterpartpronouns so that pronouns should not be understood as limiting anythingdescribed herein to use, implementation, performance, etc. by a singlegender; “exemplary” should be understood as “illustrative” or“exemplifying” and not necessarily as “preferred” over otherembodiments. Further definitions for terms may be set out herein; thesemay apply to prior and subsequent instances of those terms, as will beunderstood from a reading of the present description.

The following provides a tonneau system for use with a pickup truck. Thedescribed tonneau system includes a tonneau cover, a frame, and at leastone latch. The tonneau cover has a plurality of tonneau sections. Theplurality of tonneau sections has at least a first tonneau section and asecond tonneau section. In the following description, a third tonneausection is also included. In the following description, the sectionreferred to as the first tonneau section is the one most closelyabutting the truck cab.

A first hinge system couples the first tonneau section to the secondtonneau section, enabling stacking and expanding of the first tonneausection relative to the second tonneau section. A second hinge systemcouples the second tonneau section to the third tonneau section,enabling stacking and expanding of the second tonneau section and thirdtonneau section, when stacked, relative to the first tonneau section.When installed on a pickup truck, the frame has a first side railsecured to a first side of a cargo box of a pickup truck and a secondside rail secured to a second side of the cargo box of the pickup truck.The frame is pivotally connected to the first tonneau section distal tothe first hinge system. The at least one latch releaseably secures thetonneau cover to the first side rail and to the second side rail. Whenthe at least one latch is released, the stacked tonneau sections arepermitted to depend into the cargo box. In preferred embodiments, thisprevents or mitigates blockage of the rearview window of the pickup cab.

An exemplary tonneau system 20 for use with a pickup truck 24 is shownin FIG. 1. The tonneau system 20 includes a tonneau cover 28 covering acargo box of the pickup truck 24. The tonneau cover 28 is secured in anunfolded (expanded) state to a frame that includes two side rails 32that are secured to the side walls of the cargo box. A back edge 36 ofthe tonneau cover 28 lies adjacent a tail gate of the cargo box. Autility rack 40 is optionally secured to front end of each of the siderails 32 for securing large apparatus such as ladders thereto.

FIGS. 2a, 2b , and 3 show the tonneau cover 28 and frame 38 of thetonneau system 20 in more detail. The tonneau cover 28 can have aplurality of sections, but in the illustrated example, has four tonneausections 44 a, 44 b, 44 c, and 44 d. The number of sections can bedetermined by designing the sections so that they are no longer than theheight of the truck bed for reasons that will become apparent. It ispossible that the sections can be slightly longer than such heightdepending on the location of a hinge member on the section closest tothe truck cab, again for reasons that will become apparent.

The tonneau sections 44 a, 44 b, 44 c, and 44 d have hinge systems therebetween to pivotally couple them. The hinge systems in this embodimentare piano hinges and spacer members used to enable nested stacking ofthe tonneau sections 44 a, 44 b, 44 c, and 44 d one atop another forminga stack 45 as seen in FIG. 12. In particular, a first spacer member 48 apivotally couples the tonneau section 44 a that is closest to the frontof the cargo box when deployed and the adjacent tonneau section 44 b viapiano hinges 50. A second spacer member 48 b pivotally couples thetonneau section 44 b to the adjacent tonneau section 44 c via pianohinges 50. The tonneau section 44 c is pivotally coupled to therear-most tonneau section 44 d via piano hinge 50.

In the embodiment shown, the tonneau sections 44 a, 44 b, 44 c, and 44 dand the spacer members 48 a and 48 b are constructed from aluminumpanels housing a honeycomb structure therein to provide rigidity. Rubberor other suitable wipers, gaskets or sealing mechanisms (not shown) maybe provided in between the tonneau sections and spacer members toprevent liquid ingress to the truck bed. Similarly, suitable wipers,gaskets or sealing mechanisms 96 may be provided between the frame siderails 32 and the tonneau cover 28 to prevent liquid ingress.

The frame 38 includes a front cross member 52 spanning the two siderails 32 at a front end thereof. The front end is adjacent the truck cabwhen the tonneau system is placed upon a truck bed.

A pin slot 56 is located along each side rail 32 for receiving a pin 58projecting from each side of the tonneau section 44 a distal from thefirst spacer member 48 a.

A utility track 60 is located along the top of each side rail 32. Theutility track 60 enables various attachments to be secured to the siderail 32 for securing tools, tool boxes, and the like thereto. Theutility track 60 may be vented by one or more apertures along a rearand/or bottom surface thereof to permit water to drain from the utilitytrack 60.

A pair of front latches 64 secures the tonneau section 44 a at a rearend thereof to the side rails 32 to retain the first tonneau section inan extended position. A pair of rear latches 68 secures the tonneausection 44 d at a rear end thereof to the side rails 32 to retain thetonneau cover as a whole in an extended position.

An alternative embodiment is shown in FIG. 28, in which a dead panel 702is provided ahead of the first tonneau section 44 a. In this case, ahinge 704 couples the dead panel 702 to the first tonneau section 44 aso that the first tonneau section 44 a can be pivoted into the bedduring use. The dead panel is fixed in orientation to the frame, forexample being integrated therein or fastened thereto.

FIG. 4 shows the pin slot 56 of the left side rail 32 having a notchedtop opening 72 and a generally rearward-sloping channel. The right siderail 32 has a corresponding pin slot 56 with a similar notched topopening 72 and a generally rearward-sloping channel.

FIG. 5 shows a pin 58 located on a left side of the tonneau section 44 athat is received by the pin slot 56 of FIG. 4. The pin 58 has a flatprotrusion 80. A cap 71 may be removably engaged to the top of thenotched top opening 72 to retain the pin 58 in the slot 56 for furthersecuring the pin from sliding out of the side rail 32 during operation.The cap 71 is a thin plate 73 that has a protrusion 75, allowing it toslide over the side opening of the notched top opening 72, preventingthe tonneau cover's pin 58 from sliding out of the rail 32 duringoperation.

In another embodiment, the protrusion 80 of the pin 58 may be round topermit easier removal of the pin 58 from the slot 56. It will beappreciated that it is possible to remove the tonneau cover 28altogether and utilize the frame with the pin slot 56 to engage a thirdparty cover for the truck bed. For example, a soft cover or other devicecould be adapted to fit the frame.

As shown in FIG. 6, when the tonneau section 44 a and pin 58 areoriented vertically, the flat protrusion 80 of the pin 58 is received bythe notched top opening 72 of the slot 58 to allow the pin 58 to enterthe channel of the pin slot 56.

FIG. 7 shows the tonneau section 44 a oriented horizontally afterinsertion of the pins 58 through the notched top opening 72 into the pinslots 56 of the side rails 32. As will be understood, upward lifting ofthe tonneau section 44 a is prohibited by abutting of the flatprotrusion 80 of the pin 58 against the notched top opening 72 of thepin slot 56, thereby securing the front of the tonneau section 44 a tothe side rail 32.

As will be appreciated, by reorienting the tonneau cover 28 such thattonneau section 44 a is disposed vertically relative to the side rails32, as shown in FIG. 6, when it is deployed on the pickup truck 24, thetonneau cover 28 can be removed from the pickup truck 24, thus providingfull access to the cargo box. The tonneau cover 28 can then be storedelsewhere or in the cargo box until required again.

FIG. 8 shows a cross section of the right side rail 32 atop a sidewall82 of the cargo box of the pickup truck 24 at line A-A in FIG. 1. Asshown, the side rail 32 has a utility track 60 along a top edge thereof.The side rail 32 is clamped along a vertical portion 84 thereof to thesidewall 82 of the pickup truck 24 by a clamp 86. A side utility track88 is positioned along the vertical portion 84 to enable variousattachments to be secured to the side rail 32 inside the cargo box forsecuring tools, tool boxes, and the like thereto. The attachments aregenerally additional components to be mounted inside the cargo box or toallow secondary mounting for accessories that require additional supportlike seating or items that will hold heavy cargo loads. Attachments maybe securable to either or both of the side utility track 88 and theutility track 60 so that the utility tracks 60, 88 can acceptindependent accessories (one thing mounted to the top and a separatething mounted to the inside) or one item that mounts in both slotssimultaneously for additional support/rigidity. The inner utility trackends at the tonneau section 44 a so that the tonneau cover can passthrough to depend into the cargo bed without being obstructed by theinner utility track.

The side utility track 88 may be vented by one or more apertures along arear and/or bottom surface thereof to permit water to drain from theinner utility track 88.

A tonneau rest 92 projects perpendicularly from the vertical portion 84to provide a horizontal support for the tonneau cover 28. A sealingstrip 96 is adhered to the upper part of the vertical portion 84 of theside rail and along the top surface of the tonneau rest 92 to provide awater-resistant seal and to dampen movement of the tonneau cover 28during travel of the pickup truck 24. A flexible upper lip 100 of thetonneau cover 28 helps cover the gap between the tonneau cover 28 andthe side rail 32.

FIG. 9 shows a cross section of the right side rail 32 atop of thesidewall 82 of the cargo box of the pickup truck 24 at line B-B inFIG. 1. As shown, the side utility track 88 and tonneau rest 92 continuefrom the back end of the side rail 32 until just before the back edge ofthe tonneau section 44 a when the tonneau section 44 is orientedhorizontally. The profile of the side rail 32 further front from that isas shown in FIG. 9. The tonneau cover 28 does not rest on a horizontalsurface at the front end of the side rail 32.

FIGS. 10 and 11 show the tonneau cover 28 being pivoted about the pin 58in the pin slot 56 from a position in which the nested stacked tonneaucover 28 depends generally vertically into the cargo box to a generallyhorizontal position. To achieve the vertical orientation of the nestedstacked tonneau cover, a latch and catch system may be used. Referringnow to FIG. 10, the front latches 64 include a catch 104 secured to theside utility track 88 and a latchbolt 108 on a flange 112 extending froma rear bottom surface of the tonneau section 44 a. The latchbolt 108includes an actuator 114 to which a cable is fastened. The cable is thenfastened to the actuator 114 of the corresponding latchbolt 108 on theother side of the tonneau section 44 a. Pulling the cable releases thelatchbolts 108 from the catches 104 to permit free pivotal movement ofthe nested stacked tonneau cover 28. The actuating of the actuator maybe accomplished by hand or electrically.

As shown, the tonneau cover 28 has clearance 90 from the forward end ofthe inner side utility track 88 when nested and stacked to pivot aboutthe pin 58 from a position in which it depends generally vertically inthe cargo box to a position in which the tonneau cover 28 is generallyhorizontal and above the cargo box.

FIG. 11 shows the nested stacked tonneau cover 28 in a horizontalorientation with the front latch 64 engaged to restrict pivoting of thenested stacked tonneau cover 28.

FIG. 12 shows the horizontal position of the nested stacked tonneaucover 28 when the front latches 64 are engaged. The front latches 64 aresufficiently robust to support the weight of the tonneau cover 28thereon.

FIG. 13 shows the rear end of the left side rail 32. A catch 116 of therear latch 68 is shown secured to the side utility track 88.

FIG. 14 shows the underside of the tonneau cover 28 wherein a latchbolt120 of the tonneau section 44 d is engaged with the catch 116 to securethe tonneau cover 28 in a fully extended and horizontal position inwhich it covers the cargo box of the pickup truck 24. In this extendedhorizontal position, the rear three tonneau sections 44 b, 44 c, and 44d rest atop of the tonneau rests 92 of the side rails 32. Like thelatchbolt 108, the latchbolt 120 includes an actuator 122 to which acable is fastened. The cable is then fastened to the actuator 122 of thecorresponding latchbolt 120 on the other side of the tonneau section 44d.

In order to put the tonneau cover 28 into the nested stacked horizontalposition shown in FIG. 12, the cable between latchbolts 120 is pulled torelease the latchbolts 120 from the catches 116. Once the rear latches68 are released, the tonneau section 44 d can be pivoted upward andforward about the hinge 50 into a stacked position atop of the tonneausection 44 c. Stacked tonneau sections 44 c and 44 d can then be pivotedupward and forward about the second spacer member 48 b into a stackedposition atop of the tonneau section 48 b. Similarly, nested stackedtonneau sections 44 b, 44 c, and 44 d can be pivoted upward and forwardabout the first spacer member 48 a into a stacked position atop of thetonneau section 48 a, which is locked in a horizontal position via thefront latches 64.

Releasing the front latches 64 allows the nested stacked tonneau cover28 to be pivoted downward so that it depends into the cargo box, asshown in FIG. 15. As the pivot axis 59 of the pin 58 and pin slot 56 areclose to the front edge of the cargo box, the nested stacked tonneaucover 28 tucks into the cargo box proximal to a front wall of the cargobox. Thus, in this manner, the tonneau cover 28 can be first stacked ina nested manner above the cargo box in a first position and then pivotedinto the cargo box in a second position at the front edge thereof,thereby requiring little clearance inside the cargo box proximal to thefront edge thereof. When the nested stacked tonneau cover 28 is pivoteddown into the cargo box, it only occupies about a foot of cargo room atthe front of the cargo box.

Alternatively, when the front latch 64 is released, the nested stackedtonneau cover 28 can be pivoted upwards and forwards to provide accessto the cargo box, as shown in FIG. 16.

FIG. 17 shows the position and orientation of the pin 58 of the tonneausection 44 a relative to the pin slot 56 when the nested stacked tonneaucover 28 pivoted vertically upwards above the cargo box.

FIG. 18 shows a side view of the nested stacked tonneau cover 28 whenoriented vertically above the cargo box. As shown, the nested stackedtonneau cover 28 nests inside the utility rack 40 in this position.

FIG. 19 shows a pair of struts 128 pivotally connected to the bottomsurface of the tonneau section 44 a that can be snap connected tolocations along the side rails 32 to maintain the nested stacked tonneaucover 28 in a generally upright position above the cargo box to provideaccess to cargo stored at the front end of the cargo box. When no longerrequired, the struts 128 are unsnapped from the side rails 32 so thatthe nested stacked tonneau cover 28 is free to pivot. In anotherembodiment, as shown in FIG. 28, a dead panel 702 in fixed relationshipto the rails has one or more locking hinges 704 that are activated bycables 706, that allow the cover 28 to rotate upwards or downwards andlocking at various angles, e.g., in 45 degree increments.

While in the above-described embodiment, the tonneau sections areprimarily made of an aluminum shell housing a honeycomb structure, itcan be desirable to modify their structure in certain scenarios.

FIG. 20 shows a tonneau system 200 in accordance with another embodimentthat is similar to the previously described embodiment and illustratedin FIGS. 1 to 19, wherein solar panels 218 are installed on the topsurface of a tonneau cover 204. Preferably the panels 218 are fastened,for example with screws or bolts and nuts, to be easily removable forservice, repair, or upgrades. For example, solar panels can beinterchanged with metal panels to add or remove solar function. Thetonneau cover 204 rests between a pair of side rails 208. Like thetonneau cover 28 shown in FIG. 1, the tonneau cover 204 includes fourtonneau sections 212 a, 212 b, 212 c, and 212 d. The tonneau sections212 a, 212 b, 212 c, and 212 d have hinge systems there between topivotally couple them. The hinge systems are piano hinges and spacermembers 216 a and 216 b are used to enable nested stacking of thetonneau sections 212 a, 212 b, 212 c, and 212 d one atop another. Inparticular, a first spacer member 216 a pivotally couples the tonneausection 212 a that is closest to the front of the cargo box whendeployed and the adjacent tonneau section 212 b via piano hinges. Asecond spacer member 216 b pivotally couples the tonneau section 212 bto the adjacent tonneau section 212 c via piano hinges. The tonneausection 212 c is pivotally coupled to the rear-most tonneau section 212d via a piano hinge.

The tonneau section 212 a and the spacer members 216 a and 216 b areconstructed from aluminum panels housing a honeycomb structure thereinto provide rigidity. The tonneau sections 212 b, 212 c, and 212 d areconstructed having solar panels 218 along their top surfaces.

A utility rack 220 has a brake light aperture 224 along a top barthereof to enable visibility of the brake light at the top of the rearof the cabin when the tonneau system 200 is deployed thereon.

In order to transfer power generated from each solar panel 218 intonneau sections 212 b, 212 c, and 212 d, the solar panels 218 arecoupled to a battery that stores the power.

FIG. 21 shows the electrical cabling system employed with the tonneaucover 204. A plug 228 on the bottom of tonneau section 212 d adjacentthe front edge thereof receives a cable 232 that extends from a sheath236 on the bottom surface of the tonneau section 212 c adjacent a rearedge thereof. The cable 232 is rigid enough to resist bunching andpinching between the tonneau sections 212 c, 212 d when they abut oneanother in an expanded state. The sheath 236 extends into the tonneausection 212 c and is sufficiently long enough to permit compression ofthe cable 232 therein when the tonneau section 212 d is stacked atop ofthe tonneau section 212 c. The cable 232 can be unplugged from the plug228 to permit disassembly of the tonneau cover 204, for example, toreplace a tonneau section having a faulty solar panel. Such cabling andconnections are employed between tonneau sections 212 a, 212 b, 212 c,and 212 d and spacer members 216 a and 216 b. As will be understood, theslack length of the cable 232 between tonneau sections 212 c, 212 b, 212a and spacer members 216 b, 216 a is not as great as between the tonneausection 212 c and the tonneau section 212 d.

Each solar panel 218 may require its own cable to the battery. As aresult, there may be two cables 232 between the tonneau section 212 cand the tonneau section 212 b, and three cables 232 between the tonneausection 212 b and the tonneau section 212 a.

FIG. 22 is a schematic diagram of the power elements of the tonneausystem 200 relative to a pickup truck 240 in which it is deployed. Aninlet plug 244 can receive three cables from the tonneau section 212 a.The cables are sufficiently long to permit pivoting of the tonneau cover204 when stacked in a nested manner. The inlet plug 244 has a cable 248extending back between the side rail 208 and the sidewall of the cargobox of the pickup truck 240. The cable 248 extends to a battery 252 in aretaining basket secured to a side utility track of the side rail 208.The battery 252 receives the power generated by the solar panels 218 andstores it. A transformer outlet 256 is coupled to the battery 252 fordrawing power therefrom, converting it to alternating current, andpowering a set of power outlets, such as a standard 220 volt householdoutlet, a USB port, etc. In this way, tools can be charged using solarpower when they are not being used and when the tonneau cover 204 isextended to cover the cargo box of the pickup truck 240.

FIG. 23 shows a variation of the tonneau system of FIG. 20, wherein, atonneau cover 300 does not employ external cabling between tonneausections 304 a, 304 b, 304 c, and 304 d. Instead, a set of spring-loadedpins 312 along a front edge of each tonneau section 304 or spacer member308 are urged towards a set of contacts 316 along a rear edge of anadjacent tonneau section 304 or spacer member 308. The number of sets ofspring-loaded pins 312 and contacts 316 is increased from one setbetween the tonneau section 304 d and the tonneau section 304 c to twosets between the tonneau section 304 c, the spacer member 308 b, and thetonneau section 304 b, to three sets between the tonneau section 304 b,the spacer member 308 a, and the tonneau section 304 a. Further, suchsets of spring-loaded pins 312 and contacts 316 can be employed betweenthe tonneau section 304 a and a front cross-member of a frame. Use ofsuch spring-loaded pins and contacts avoids issues with the physicalwearing of external cables that are articulated regularly.

FIG. 24 shows an alternative configuration of a tonneau system 400. Aframe 402 of the tonneau system 400 has two side rails 404 that includetonneau rests 408. A tonneau cover has tonneau sections 412 a, 412 b,412 c, and 412 d, and spacer members 416 a and 416 b, similar to theconfiguration of the tonneau cover 28 of FIG. 1. A front latch 420 isshown under the tonneau section 412 a forwards from its rear edge. Thefront latch 420 has a catch that is machined into the inside surface ofthe side rail 404. The tonneau rests 408 of the side rails 404 extendforward to about the rear edge of a spacer member 416 a to permit thetonneau cover to pivot upwards or downwards unimpededly.

FIG. 25 shows a side rail 500 for use with a tonneau cover, the siderail 500 having a slot 504 that is angled forward and downward. While atonneau cover will generally remain securely therein when latched inplace, a locking bracket 508 for securing a pin of the tonneau cover inplace in the slot 504 is secured in a utility track 512 along the top ofthe side rail 500. The locking bracket 508 can be biased between an openposition, as shown, and a locking position, in which a locking slot 516on a front edge of the locking bracket 508 can engage and secure the pinof the tonneau cover, via a ridge 520. The locking bracket 508 issecured in the open and locking positions via a protuberance on theinside of the locking bracket and indentations on the side rail 500.Removal of the tonneau cover is facilitated with the slot 504 as it canbe pulled up and backward out of the slot 504 once the locking bracket508 is moved to the shown open position.

FIG. 26 shows a side rail 600 similar to that of FIG. 8 in accordancewith another embodiment, wherein the side rail 600 has a clampingelement 604 that clamps a horizontal portion of the side wall 82 of thecargo box. A rubber end 608 of the clamping element 604 is provided toreduce damage to the surface of the side wall 82 of the cargo box.

While certain configurations for the slot have been shown, those skilledin the art will appreciate that slots having other paths other thanthose shown can also be utilized. Preferably, the front of the tonneaucover cannot be lifted directly out of the slot when it is latched in,such as with a substantially vertical slot, unless additional securingmeans are employed to impede removal from the slot.

While the power elements connected to the solar panels have beendescribed as separate from the main electrical systems of a pickuptruck, those skilled in the art will appreciate that it may beadvantageous to couple the solar panels electrically to the main batteryof a pickup truck, especially in cases where the pickup truck is ahybrid or electrically-powered vehicle.

The tonneau sections may be made so as to receive either solar panels ornon-solar panels, allowing customization after purchase and replacementof a solar panel unit if faulty. Access to the panels can be providedvia a removable panel fastened to the underside of the tonneau sectionsvia screws, etc. The tonneau sections can provide a frame into which thesolar panels or non-solar panels can be fitted.

While the tonneau sections have been described as rigid above, thoseskilled in the art will appreciate that the main panels of the tonneausections, where not using solar panels, can be either rigid or flexible.Rigid panels for the tonneau sections can be constructed from, forexample, fiberglass, plastic, or metal. Alternatively, the panels can beflexible and secured over a rigid frame.

Flexible panels for the tonneau sections can be made from anyweather-resistant flexible material that is also resistant to wear, suchas vinyl coated tarpaulin.

Instead of using tonneau rests along the side rails of the cargo boxextending backward behind the first tonneau section, each of the othertonneau sections can also be held in a horizontal cover position via alocking mechanism such as the slam latches described above, etc.

As shown in FIG. 27, a retaining mechanism, such as a buckle orplurality of buckles, may be provided to maintain the sections instacked orientation. The buckle 700 may comprise two portions, one 701 aof which is secured to the first tonneau section 44 a and the other 701b to either spacer 48 b or the second tonneau section 44 b so thatclosing the buckle 700 retains the third tonneau section 44 c and fourthtonneau section 44 d nested within an envelope created by the firsttonneau section 44 a, spacer 48 a, second tonneau section 44 b andspacer 48 b.

Although the invention has been described with reference to certainspecific embodiments, various modifications thereof will be apparent tothose skilled in the art. The scope of the claims should not be limitedby the preferred embodiments, but should be given the broadestinterpretation consistent with the description as a whole.

We claim:
 1. A tonneau system for use with a cargo box of a pickuptruck, the cargo box having opposing first and second sidewalls and alsohaving a front sidewall extending between the first and second sidewallsat one end thereof and a rear sidewall extending between the first andsecond sidewalls at another end thereof, the tonneau system comprising:a first side rail configured to be respectively mounted to the firstsidewall of the cargo box; a second side rail configured to berespectively mounted to the second sidewall of the cargo box; a tonneaucover having at least two tonneau sections including a first tonneausection and a second tonneau section, the tonneau sections beingmoveable relative to one another between an unfolded state and a foldedstate, in the unfolded state the tonneau sections substantially coveringthe cargo box, in the folded state the tonneau sections being arrangedin a stack with the tonneau sections arranged one atop another, thefirst tonneau section being the tonneau section located closest to thefront sidewall of the cargo box in the unfolded state; and the stack oftonneau sections being pivotally connected to at least one of the firstand second side rails by a pivot connection, the pivot connectionincluding first and second portions being moveable between secure andrelease positions, in the secure position the stack being retaininglyengaged with the first and second side rails, in the release positionthe stack being removably engaged with the first and second side railswhereby the stack is removable from the cargo box while the first andsecond side rails remain mounted therewith.
 2. The tonneau systemaccording to claim 1, wherein one of the first and second portions ismounted to the stack and the other of the first and second portions ismounted to the first side rail.
 3. The tonneau system according to claim1, wherein one of the first and second portions is mounted to the firsttonneau section of the stack and the other of the first and secondportions is mounted to the first side rail.
 4. The tonneau systemaccording to claim 1, wherein the first portion is a pin and the secondportion includes a pin slot, the pin being received in the pin slot. 5.The tonneau system according to claim 4, wherein the pin projects from aside of the first tonneau section that is located immediately adjacentto the first side rail when the tonneau cover is in the unfoldedposition.
 6. The tonneau system according to claim 4, wherein the firstand second side rails each include a top side and a lateral side, thelateral sides of the first and second side rails being located generallyopposite from one another when the first and second side rails aremounted to the first and second sidewalls of the cargo box, the top sideof the first and second side rails facing out of the cargo box when thefirst and second side rails are mounted to the first and secondsidewalls of the cargo box, the pin slot is provided in the first siderail and includes a top opening formed in the top side of the first siderail, the pin slot further including a channel extending from the topopening.
 7. The tonneau system according to claim 6, wherein the channelis open on the lateral side of the first side rail.
 8. The tonneausystem according to claim 7, wherein at least a portion of the pin has across-section of a non-round shape presenting a different width in adirection of the top opening in each of the secure position and therelease position, at least a portion of the top opening having a widthcorresponding to the width of the non-round shape in the releaseposition whereby the pin in the release position can pass through thetop opening and the stack of tonneau sections removed from the siderails.
 9. The tonneau system according to claim 8, wherein the width ofthe non-round shape in the release position is smaller than the width ofthe non-round shape in the secure position.
 10. The tonneau systemaccording to claim 8, wherein the non-round shape is provided as aprotrusion of the pin.
 11. The tonneau system according to claim 10,wherein the protrusion is on an end of the pin.
 12. The tonneau systemaccording to claim 8, wherein the non-round shape is provided as a flatprotrusion of the pin.
 13. The tonneau system according to claim 8,wherein adjacent to the non-round shape the pin is provided with across-section having a round shape.
 14. The tonneau system according toclaim 8, wherein the non-round shape is provided as a protrusion of thepin.
 15. The tonneau system according to claim 6, further comprising acap removably engaged with the side rail and extending over the topopening whereby removal of the pin through the top opening is inhibited.16. The tonneau system according to claim 15, wherein in the releaseposition, the pin is located immediately below the top opening.
 17. Thetonneau system according to claim 15, wherein the channel extends alonga length of the first side rail.
 18. The tonneau system according toclaim 17, wherein the pin is slidingly received within the channel. 19.The tonneau system according to claim 18, wherein in the secureposition, the pin in located in a portion of the channel extending alongthe length of the first side rail.
 20. The tonneau system according toclaim 1, wherein the stack of tonneau sections is pivotally connected toeach of the first and second side rails by a pivot connection.
 21. Thetonneau system according to claim 1, wherein in the secure position ofthe pivot connection, the first tonneau section is generally parallel toa plane defined by the first and second side rails.
 22. The tonneausystem according to claim 1, wherein in the secure position of the pivotconnection, the first tonneau section is horizontal oriented.
 23. Thetonneau system according to claim 1, wherein in the release position ofthe pivot connection, the first tonneau section is generallyperpendicular to a plane defined by the first and second side rails. 24.The tonneau system according to claim 1, wherein in the release positionof the pivot connection, the first tonneau section is verticallyoriented.
 25. The tonneau system according to claim 1, wherein in therelease positon of the pivot connection, the stack of tonneau sectionsdepends from the first and second side rails into the cargo box of thepickup truck.
 26. The tonneau system according to claim 1, wherein thepivot connection is spaced apart from an end of the at least one of thefirst and second side rails.
 27. The tonneau system according to claim1, wherein the tonneau sections are one of rigid and flexible.